Metal injection molded grooved face insert

Abstract

The present invention discloses an iron-type golf club head having a face insert composed of a metal injection molded material. The face insert having a plurality of grooves disposed therein.

Description

CROSS REFERENCES TO RELATED APPLICATIONS[0001]The present application claims priority to U.S. Provisional Patent Application No. 61 / 295,094 filed on Jan. 14, 2010.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT[0002]Not ApplicableBACKGROUND OF THE INVENTION[0003]1. Field of the Invention[0004]The present invention relates to iron-type golf clubs heads with face inserts. More specifically, the present invention relates to iron-type golf clubs heads with metal injection molded face inserts.[0005]2. Description of the Related Art[0006]Present day golf clubs are typically composed of titanium or steel, and either cast or forged. Various patents have disclosed the use of multiple material golf club heads, generally combining a metal with a non-metal. Various patents have also disclosed the use of metal injection molding for golf clubs.[0007]Sanford et al., U.S. Pat. No. 5,665,014, for a Metal Golf Club Head And Method Of Manufacture, discloses a golf club head with two co...

AI Technical Summary

Benefits of technology

[0036]An object of the present invention is to accomplish a method of manufacture and design such that grooves can be produced with detailed features, tight profile tolerances and steep groove wall angles on a face insert for an iron or wedge. The advantage in being able to do this is that spin will be enhanced for a variety of shot types and conditions when striking a urethane covered golf ball.

[0037]The present invention consists of using a specific manufacturing process, metal injection molding, “MIM”, to fabricate a face insert having integrally molded grooves. The grooved face plate is made from a metal material, most preferentially made via injection molding using a fine particulate formulation of metallic and plastic particles (such as MIM 17-4PH provided by Kinetics) to enhance precise replication of the groove geometry. The groove geometry fabricated using this method can be controlled more precisely which enables increased engagement with the ball during impact, causing increased spin on the ball. The groove geometry is precision machined in a negative tool surface and the MIM material is formed against the tool surface and subsequently sintered to final form.

[0039]The advantages of using a MIM face insert groove profile include the fact that it can be replicated more consistently, essentially yielding tighter tolerances and allowing the nominal groove geometry to be designed closer to the allowable limits defined by the USGA.

Problems solved by technology

Although these inventions have provided novel methods for forming grooves on the face of the golf club head, the prior art has not optimized groove formation.

Materials and processes typically used in fabrication of golf clubs are not amenable to precision control of a finely detailed groove profile.

Forging, forming, casting and machining of metals all have practical limitations with regard to the feature size and profile tolerance that can be accurately and consistently replicated in mass production.

Detailed features, tight profile tolerances and steep groove wall angles are not suitable for existing methods of manufacture using conventional materials such as stainless steel, carbon steel, titanium, aluminum and the like.

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